Shipping container for bathtubs

ABSTRACT

A shipping container is described for large, heavy plumbing fixtures, such as bathtubs and the like. The container includes a pair of reinforced and folded end frames that are positioned at each end of the bathtub, and, a continuous wrapper element which encloses the bathtub. The wrapper is secured to the sides of the end frames and includes top, bottom and side panels which extend around the bathtub to provide a durable, convenient, and inexpensive shipping container.

O Umted States Patent 1 1 1111 3,797,653 Goodsite 1 Mar. 19, 1974 [54] SHIPPING CONTAINER FOR BATHTUBS 3,289,825 12/1966 Smith 229/ 14 C 3,486,612 12/1969 Kivell 206/46 H [75] Invent James Gmdsm, Sanduskyi Ohm 3,521,744 7/1970 Smith...- 206/46 H [73] Assignee: .Westvaco Corporation, New York,

Primary Examiner-William T. Dixson, Jr.

[22] Filed: Mar. 10, 1972 211 Appl. No.: 233,510 [571 ABSTRACT A shipping container is described for large, heavy [52 us. c1. 206/320 229/14 0 Plumbing fixtures- Such as bathtubs and like- The [51] hm CL d s m gga gsyz container includes a pair of reinforced and folded end [58] Field 'search 2O6/46 H 6 FN 46 frames that are positioned at each end of the bathtub, {29/14 6 and, a continuous wrapper element which encloses the bathtub. The wrapper is secured to the sides of the [56] References Cited end frames and includes top, bottom and side panels which extend around the bathtub to provide a durable, 3 680 688 3 2? STATES PATENTS convenient, and inexpensive shipping container.

, /l Smith 206/46 H 2,974,844 3/1961 Lane 229/14 C 1 Claim, 8 Drawing Figures PATENTED HA8 1 9 I974 SHEET 1 0F 3 SUMMARY OF INVENTION The present invention relates to a shipping container, and more particularly to a shipping container for large, heavy plumbing fixtures, such as bathtubs and the like.

Large, heavy plumbing fixtures require specially constructed shipping containers to prevent them from being damaged during shipping, storage, or other handling. Bathtubs in particular are difficult to package because of their large size and weight, their irregular shape, and the susceptibility of their vitreous surfaces to chips and scratches.

In the past, plumbing fixtures such as bathtubs were packaged and shipped in containers fabricated from wood or' corrugated fiberboard or a combination thereof. However, the known containers were expensive to manufacture and required considerable effort and time for positioning the bathtub within the container. Moreover, the known containers did not provide any specially adapted structure for supporting the portions of the bathtub best suited for bearing the weight of the tub during shipment. In addition, the known containers did not provide any support means integral with the primary structure of the container for supporting and spacing the bathrub from the sides of the wrapper enclosing the tub.

Accordingly, it is the basic object of this invention to provide an improved means for enclosing, protecting and facilitating the handling of heavy plumbing fixtures such as bathtubs, however, it should be clear after considering the disclosure herein as a whole, that other similarly shaped objects could just as readily be packaged with the novel container described using the same principles set forth.

More specifically, it is the principal object of this invention to provide a shipping container for bathtubs which is low in cost; convenient and easy to store, handle and assemble; is adaptable to semi-automatic assembly; is effective in protecting the bathtub during shipment; is durable so as to resist both rough handling and exposure to the elements; has a smooth and neat exterior design for ease of handling; haslarge areas provided for printed or other advertising matter; and, is easy and quick to disassemble.

Briefly, these objects are attained in the shipping container disclosed herein by the use of novel reinforced end frames in combination with an outer wrapper element which completely encloses the bathtub upon assembly. Each novel end frame comprises a cut and scored twin-panel element with strategically located reinforcing elements positioned thereon. The end frames are shaped so as to become interlocked with the bathtub during assembly of the container, and further include areas along three sides thereof to provide space for securely attaching the outer wrapper thereto. Accordingly, the novel end frames disclosed herein derive their strength both from the strategic positioning of the reinforcing elements between the bathtub and the panels of the end frame, and, from the fact that the outer wrapper which encloses the bathtub is securely fastened to the end frame panels.

A significant contribution to the attainment of the overall combination of advantages set forth above lies in the fact that the shipping container disclosedherein, including the novel reinforncing elements, is constructed completely from corrugated paperboard. In addition, each of the three basic elements which make 1 up the parts of the shipping container disclosed herein,

may be shipped to the user in flat blank form where they may be set-up quickly and easily for packaging the bathtubs. Furthermore, in one embodiment of the present invention, a novel tab construction is provided for correctly positioning, and, maintaining the position of the end frames, with respect to the outer wrapper of the container, thereby permitting assembly of the container on a table or an assembly line with semiautomatic convenience.

In summary, the invention to be described in more detail hereinafter attains each and every one of the objectives set forth above. Moreover, further objects, advantages and details will become evident from the following description, drawing and claims.

IN THE DRAWING FIG. 1 shows inblank form the outer wrapper of the present invention;

FIG. 2 shows in blank form one of the end frame members required for the present invention;

FIG. 3 shows a partial view in blank form of one of the end frame members of the present invention with reinforcing elements positioned thereon;

FIG. 4 is a perspective view showing a bathtub positioned on the outer wrapper of the present invention withthe right end frame partially folded into position; 1

FIG. 5 is a partial perspective view from the back of the arrangement shown in FIG. 4 illustrating the right end frame folded into position adjacent the bathtub and prior to being secured to the outer wrapper;

FIG. 6is a partial view of the blank of FIG. 2 showing a second embodiment of the present invention;

FIG. 7 is a partial view of the blank of FIG. 1 showing a second embodiment of the present invention; and,

FIG. 8 is a partial perspective view showing the second embodiment of the invention with the end frame positioned and retained on the outer wrapper.

DETAILED DESCRIPTION- The principal parts of the present invention comprise an outer wrapper 10 shown in FIG. 1 and a pair of reinforced end frame members 30 (one shown in FIG. 2). The outer wrapper'includes, in no particular order, a series of panels l1, l2, l3 and 14 which form the bottom, top and side panels of the outer enclosure. Each of the panels I1, l2, l3 and 14 are separated from one another along fold lines 15, 16 and 17 with an additional fold line 18 separating panel 14 from the closure flap 19. The outer wrapper 10, as shown in FIG. 4, lies flat before it is folded around the tub. However, after it is around the bathtub, the closure flap 19 is secured to the first panel I I by any known and desirable means including staples, adhesive or stitching. Finally, the outer wrapper 10 also includes end flaps 23, 24 at each end of the panels 11, 12, 13 and 14 for folding inwardly at the ends of the outer wrapper in a manner to be described more fully hereinafter.

FIG. 2 illustrates in blank form one of a required pair of end frame members for the shipping container disclosed herein. The end frame member 30 comprises a two panel construction 32, 31 separated from one another along fold line 33, with end flaps attached at one end thereof. Panel 32 of the end frame member 30 has a pair of articulated panels 35, 37 attached at one side thereof along the fold line 34, with a fold line 36 dividing the two articulated panels 35, 37 from one another. These panels 35, 37 serve, in the assembled condition, as bracing members for the front skirt of the bathtub as packaged. Obviously, articulated panels could also be employed at both sides of panel 32 if desired, and if necessary to securely brace the bathtub in the package at both sides. Panel 31 of the end frame member 30 includes a single flap 39 at the side edge thereof and sep arated therefrom along a fold line 38, and, an additional single flap 42 at the bottom edge thereof and separated therefrom by a fold line 41. The side flap 39 of end frame panel 31 serves in the assembled condition as a protective and cushioning means for the edges and front face of the skirt of the bathtub while the bottom flap 42 of end frame panel 31 provides space for the inclusion of a reinforcing element 44 (FIG. 3) along the top side edge of the bathtub as packaged. And, finally, it will be noted that panel 31 of the end frame member 30 includes a hand hole cut-out 40 to assist in handling the packaged bathtub.

FIG. 3 shows the end frame member 30 with the reinforcing elements 43 and 44 positioned thereon. In the preferred embodiment of the present invention, the reinforcing elements 43 and 44 are fixed to the panels 31 and 42, however, it is within the scope of the present invention to simply place the elements 43, 44 loosely on the panels 31, 42 during the packaging of the bathtub. In addition, the reinforcing elements 43, 44 are, in the preferred embodiment, fabricated from glued sections of corrugated paperboard laid up to achieve the desired thickness. However, it should be apparent from the present disclosure that a serially scoredsheet of corrugated paperboard could just as readily be employed, after the panels thereof were folded into overlapping relationship. Furthermore, wooden, plastic, or foam elements, or even fiberboard elements could be used in place of the preferred corrugated paperboard reinforcing elements described herein.

FIG. 4 illustrates the manner in which the outer wrapper l and the paired end frame members 30 are placed around the tub. Note that the bathtub 54 is turned upside down with the front apron or skirt 50 thereof forward. The bathtub also includes a top flange 53 and a pair of rear legs 5 1, 52. Thus, the type of bathtub illustrated is one that is built into a space provided therefor in the bathroom. Other bathtubs of a different style which are not built-in may include skirts or aprons at each end thereof. However, the container of the present invention would be just as suitable for packaging a bathtub with side aprons as the tub illustrated herein.

For the purpose of assembling the package as shown in FIG. 4, the wrapper is initially laid out as illustrated with the scored side up and the paired end frame members are placed in position on one of the panels (shownon panel 12) of the outer wrapper. In the case illustrated, the reinforcing members 43, 44 are already positioned and secured to the end frame panel 31 and bottom flap 42, although as pointed out hereinbefore, eachof the reinforcing elements 43, 44 could just as readily be located in place just prior to lowering the bathtub onto the wrapper. However, as shown in FIG. 4, after the pre-formed end frame members 30 are positioned on the outer wrapper 10, the bathtub is lowered into position open side down, with the top flange 53 of the tub resting on the reinforcing elements 43, 44.

Next, the end frame members 30 are folded over about the fold line 33 separating panels 31 from 32, and the articulated flaps 35, 37 are reverse folded to fit snugly behind the front apron 54 of the tub.

At this point in the assembly of the package, reference to FIG. 5 of the drawing will show the articulated flaps 35, 37 in their supporting position behind the front apron 54 and locked into place by a structural element 55 which braces the tub body from the apron 54. In this position, the panel 32 comes into contact with another structural element 57 attached to the tub and the panel 31 of end frame member 30 assumes an upright position thereby bringing the reinforcing element 43 into intimate relationship with the side edges of the top flange 53 of the tub.

Thus, the novel end frame members 30 of the present invention clearly offer reinforced support and protection to the packaged tub both from the top and sides of the flange 53 of the tub. In addition, with the side flaps 39 of end frame panel 31 folded around into contact with the apron 54 of the tub, additional space is provided along the front of the apron 54 to prevent damage thereto. Accordingly, the bathtub is located within the package so as to be spaced from the walls thereof, and the end frame members 30 present the panels 31 thereof in a position which enables the end flaps 23 and 24 of the outer wrapper panels 11, 12, 13 and 14 to be safely secured thereto. Moreover, the size of the panels 31 of the end frame members 30 is chosen so as to provide a clearance over the feet 51, 52 of the bathtub when the outer wrapper is folded around the tub and secured together along the closure flap 19.

The preferred method for securing the end flaps 23, 24 of the outer wrapper panels 11-14 to the end frame panels 31 is by stapling, however other securing means could just as readily be used. Furthermore, as pointed out hereinbefore, simply by securing the end flaps 23, 24 to the panel 31, yields additional integrity and strength to the entire package. With the end flaps 23, 24 so attached, and, with the end frame members 30 in position to place the reinforcing elements 43, 44 in closely abutting relationship to the top and sides of the flange 53 of the tub, the tub becomes more than adequately located within the container to achieve each of the advantages pointed out in the objects of the invention. 1

FIGS. 6-8 illustrate a second embodiment of the present invention which may be adapted to semiautomatic packaging techniques. The lower part of the end frame member 30 shown in FIG. 6 includes, in addition to the reinforcing elements 43, 44, a cut-out 45 adjacent to the fold line 41 dividing the panel 31 from the bottom flap 42. This cut-out 45 in the end frame members 30 is provided therein to assist in locating the end frame members on the outer wrapper 10 during assembly. FIG. 7 shows a partial view of the outer wrapper 10 with paired tabs 25 cut into panel 13 thereof to cooperate with the cut-outs 45 in the end frame members 30. It should be appreciated, however, that the tab elements 25 could just as readily be cut from one of the other panels of the outer wrapper 10, as desired, and panel 13 was chosen only for the sake of convenience. Finally, FIG. 8 shows the different parts of the second embodiment hereof, in their cooperating relationship with an end frame member 30 properly located on the outer wrapper 10. Note that the tab element 25 cut from the outer wrapper panel 13 has been inserted in the cut-out 45 located in the end frame member 30. This manipulation of the parts of the package aids in the assembly of the container on an assembly line or a table top as desired. For this embodiment, the reinforcing elements 43, 44 would be previously secured to the end frame panels 31 and 42 to assist the workmen in the final packaging assembly.

Thus, by providing reinforced end frame members 30 that may be fitted to the ends of the packaged bathtub, in combination with a continuous wrapper that not only surrounds all sides of the bathtub, but is also attached to the end frame members, a package is achieved which protects all of the vitreous coated surfaces of the bathtub that are especially susceptible to damage. Moreover, the complete enclosure provided by the present invention prevents the entry of any debris or other foreign matter into the package. And a smooth exterior surface is achieved on all sides of the container to permit ease of handling.

Thus the invention disclosed herein provides a new and improved shipping enclosure, that, compared with the prior art packages, is considerably less expensive in terms of costs of material and labor involved in construction, assembly and disassembly. Further, the novel container disclosed herein provided a lightweight, strong and durable shipping enclosure for packaging bathtubs that resists twisting, and that protects the bathtub against damage during shipment and when stored.

The invention in its broader aspects is not limited to the specific details shown and described, and changes therein may be made in such details without departing from the principles of the invention as disclosed in the appended claims.

I claim:

1. A shipping container for bathtubs or the like in the form of a complete enclosure for said bathtub, comprising:

a. a single sheet outer wrapper portion including a seb. a pair of reinforced end frame members fitted to the ends of said bathtub, each of said end frame members comprising a two panel construction with a first panel of each end frame lying in an upright position and spaced from the end of said bathtub said first panel including a flap at one end thereof for protecting and cushioning the front face of said bathtub by providing a space between the outer wrapper and the front face of the bathtub, and a second flap at one edge thereof for protecting and cushioning the top face of said bathtub, each of said second flaps and first panels including separate reinforcing elements constructed from glued sections of corrugated paperboard rigidly attached thereto for supporting the top face and end edges of said bathtub in spaced relation from the outer wrapper and the end frame members, and a second panel of each end frame abutting the end of said bathtub to brace said bathtub said second panel including a pair of articulated panels foldably attached thereto and abutting the ends of said bathtub for providing additional bracing support to said bathtub;

. a tab element locating means at each end of the bottom outer wrapper panel which cooperates with a slot in each end frame member for positively locating each end frame member with respect to the outer wrapper bottom panel during packaging of said bathtub; and,

d. fastening means for securing the outer wrapper panel end flaps to the first panels of each of said end frame members. 

1. A shipping container for bathtubs or the like in the form of a complete enclosure for said bathtub, comprising: a. a single sheet outer wrapper portion including a series of interconnected panels which extend around the top, bottom and sides of said bathtub, said interconnected panels further including end flaps foldably attached at each end thereof; b. a pair of reinforced end frame members fitted to the ends of said bathtub, each of said end frame members comprising a two panel construction with a first panel of each end frame lying in an upright position and spaced from the end of said bathtub said first panel including a flap at one end thereof for protecting and cushioning the front face of said bathtub by providing a space between the outer wrapper and the front face of the bathtub, and a second flap at one edge thereof for protecting and cushioning the top face of said bathtub, each of said second flaps and first panels including separate reinforcing elements constructed from glued sections of corrugated paperboard rigidly attached thereto for supporting the top face and end edges of said bathtub in spaced relation from the outer wrapper and the end frame members, and a second panel of each end frame abutting the end of said bathtub to brace said bathtub said second panel including a pair of articulated panels foldably attached thereto and abutting the ends of said bathtub for providing additional bracing support to said bathtub; c. a tab element locating means at each end of the bottom outer wrapper panel which cooperates with a slot in each end frame member for positively locating each end frame member with respect to the outer wrapper bottom panel during packaging of said bathtub; and, d. fastening means for securing the outer wrapper panel end flaps to the first panels of each of said end frame members. 